Unmanned Aerial Vehicles (UAV) is generic air vehicles that are significantly developed for military and civil purposes. In recent times, advancements in the field of UAVs are exceptional and tremendous. Nevertheless, numerous researches have been performed mainly to reduce the weight of the UAV structure. The flight time and allowable payload rely on the UAV structure's weight, which is considered a significant factor. Hence, in this paper, the UAV model's static structural behavior is cultivated utilizing the morals of Finite Element Analysis (FEA) to determine the total deformation and Von-mises stress. Three different polymer materials, namely Poly Lactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), and Polyamide (PA), are chosen for FEA analysis of 3D printed UAV structure. The thrust generated from the motors varies from 2 kg to 5 kg, and an evaluation of structural strength characteristics is performed. The FEA study has shown that maximum deformation and maximum stress are obtained at the propeller casings and the basement of the structure, respectively. After comparing the details on deformation and stress from all three materials, the research also reveals that PLA is the best material for conception. Furthermore, topological optimization is performed on the UAV structure to reduce mass and minimize stress without compromising mechanical strength. The vibrational and fatigue characteristics of optimized UAV structure is examined. The unified body of the UAV frame will reduce the assembly time and make manufacturing much more effortless.

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